Sm-2444h

Transcript

SERVICE MANUAL _2_444-1--t DN-llP POWER TRANSFER RELAYS ************************* The DN-llP Power Transfer Relay uses the same basic structure as the DN-11 Relays covered by Service Spec. SU-2444, but it has several special design features to meet the' requirements for power transfer service. DN-llP Relays are equipped with special contacts and hold-down springs on the armature to provide high back contact pressure. A rectifier is mounted on the relay connected with the coils to provide for operation on a-c. The generalinstructions givenin Service Spec. SU-2444 apply to the DN-llP Relays except for the following special details. 1. ARMATURE The armature air gap is set at the factory to a parallel value as shown in the calibration table heading, before the pole faces are painted. After painting, a check is made to see that the paint has not reduced the physical air gap by more than 0.002". For example: If a relay has been adjusted to an air gap of 0.035", the minimum physical air gap should not be less than O. 033" after painting. It should be noted that the supports for armature hold-down springs are in fairly good alignment with the guide holes in the top plate so that the springs do not have any tendency to rub or bind on the side of the holes when the armature is operated. The adjustment of the hold-down springs may be changed as neces sary to meet the calibration requirements, but a check should be made for minimum hold-down spring pressure as follows: With the relay inverted so that the weight of the armature is tending to compress the hold-down springs, the armature should not move enough to open the back contacts. It is desirable to have both adjusting screws set approxi mately the same. After all adjustments have been completed, a check should be made to see that the lock nuts on the adjusting screws are tight. Novemb~r. H:1_5JL A-2/84-100-2611-1 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./ SWISSVALE, PA 15218 UNION SWITCH 6 SIGNAl., _ RECOMMENDED T!ST INTERVALS FOR VITAL R!LAY TYPES WAYSIDE Plug-In Test Interval ORP PA PC PC-250P PC-250P! PCD PCDP · 4 Yr. 4 Yr. 2 Yr. 2 Yr. 2 Yr. 4 Yr. 2 Yr. PD 4 Yr. 4 Yr. 4 Yr. •pp PN PN-150T l Yr. 2 Yr. 2 Yr. - ·- -1. '-Yr. PNP ... PP PT 'i ·- PV . Shelf I CD CD-P COD CDP CDP-P DN DN DNL DT (D'l'-10) DX PL-28 . PM Olt•l0/11 " ' p .. ·'fC '' .. 2 Yr. _TR· • '1'P 'r'I ·- . ........ Teat Interval 4 Yr. 4 Yr. 4 Yr. 2 Yr. 2 Yr. 4 Yr. 4 Yr. 4 Yt. 1 Yr. 4 Yr. 4 Yr. 4 Yr • . 4 Yr. 2 Yr • ... 1 Yr~· - l Yr • 1 Yr. 2 Yr. VDictl Plug-In PL-59 PN-59 PN-1591 Master Te•t Interval ' '' ' Yr. Yr. Yr. Yr. . • PP-256 flasher relay• must be inspected and tested according to the followint schedule: N322561-001/101 no•inal 48 rate flasher - after not more than 10 million operation• or 4 years, whichever occurs first. N322561-002/102 nominal 65 rate flasher - after not more than 5 million operation• or 4 years, whichever occur• first. N322561-803 nominal 75 rate ·flasher - after not more than 2.5 million operation• or 4 years, whichever occurs first. ' . 1 I I t ffi U.S. & S. - 2 - 2444-H 2. CONT ACT ADJUSTMENT If the contact tips are burned so that it is necessary to file them, a very fine file (we recommend a #6 Pillar File) should be used to finish the1 rounded carbon (silver impregnated) or silver tips. This filing should be done very care fully so as to keep the tips as near as possible to the cylindrical surface with which ~y are originally provided. The contacts should be thoroughly cleaned with a '.camel 9S hair brush after this filing. After all adjustments have been completed, the contacts should be cleaned in accordance with Section 2(A) of DN-11 Relay Service Spec. SU-2444. Because of the weight of the heavy silver tips on the contact springs, it is necessary to make all checks of contact adjustment with the relay in the normal upright position. The front contacts should be adjusted with a spacer . 042" thick between the center stop pin in the armature and the pole piece. When the #1 front contact is to be used as a stick contact as required in certain circuits, this contact should be adjusted with a . 040" spacer· instead of • 042 ", so that it will open app:roximately,. 005" before the #2 contact. A celluloid tag marked "S" is assembled on the #1 front post when the contact is so adjusted at the factory. If necessary, in order to obtain calibration values, a minimum core pin spacer of 0.037" may be used for adjusting the standard front contacts, while a minimum of 0.035" may be used for adjusting the stick contact. The front contact springs should be adjusted so that when fully compressed, the front carbon tip centers on the portion of the silver contact tip which extends beyond the end of the contact spring. ADJUSTING SCREW REENFORCING Fig. 1 SPRING , U.S. & S. - 3 - 2444-H Before the back contacts are adjusted, a check should be made that the stop member is adjusted so that it barely touches the back contact spring and the contact spring will open away from the stop when the assembly is inverted. The back contact reinforcing spring should have . 020" clearance between its rounded tip and the siiver tip on the contact spring. The back contact posts should then be adjusted so that both back contacts make together, and to provide .020" (minimum) opening when the front contacts are just making. If the #1 front contact has the stick contact adjustment, the #1 back contact will have approximately 0. 025" opening when the front contact just makes. It should be noted that the contacts are properly lined up and hit approximately in the center- of the tips. The back contact reinforcing springs, which should have . 020" initial clearance from the tips of the back contact springs, as previously mentioned, should make contact with the tips approximately together as the armature moves down to compress the back contacts. With the relay fully released, the front contacts will have at least . 090" opening if all adjustments have been properly made. When standard low-voltage contacts are used on this relay, they shall have their front contacts adjusted,te make at ttie -same time as the standard power transfer front contacts •. The standard low voltage baclk.-contacts shall be adjusted to have a· l:tiiniml!,m contact opening of O~ 050" -when the front contact' is just making, but in no case shall these back contacts make before the auxiliary back contact springs strike the power transfer back contact springs. 3. BACKSTRAP On some relays thin non-magnetic shims are assembled in the joints between the cores and the backstrap to introduce a small air gap. A thin shim in the form of a washer is provided .on top of the core with another shim wrapped around the bolt to separate it from the backstrap similar to the arrangement used on quick acting relays. These shims provide a convenient method for making small changes in calihrationin the field if this should be foundnecessary because of a slight increase in rectifier resistance. If increase in rectifier resistance should cause the pick-up value of the relay to be higher than the maximum as given in Table Ill of this service specification, removal of the shim at one core will bring the pick-up value down below this maximum. 4. COILS The special connections for the coils and rectifier are shown in Figure 2, on page 4. 5. RECTIFIER (Without Relay) The following information applies only to the rectifiers which are used in combination with the power transfer relays whose internal adjustment and construction have just been given. All tests of these rectifiers should be made in the order presented on the following pages. U.S. & S. -4 - 2444-H TOP THE # 2 LEADS ARE UNDER THE COIL TAGS. Fig. 2 INSULATION TEST: With all the terminals of the rectifier jumpered together, the rectifier shall withstand, for one minute, 3000 volts, 60 cycles applied between the terminals and the bolt through the rectifier. REVERSE RESISTANCE TEST: Connect the rectifier into the circuit specified in Table I, first using the connections indicated by the solid lines. Adjust the resistor until the voltage specified in Table I is applied to the rectifier and immediately read the current. Then repeat the test with lead 'Y" connected to the other rectifier terminal as indicated by the broken line in the circuit diagram. The current for either test should not exceed that shown by the curve specified in Table I for the temperature of the rectifier at the time the test is made. U.S. & S. - 5 - 2444-H TABLE I Rectifier Pc. No. Test in Circuit of Volts In Fig. 5 Use UN196315 Fig. 4 16 Curve "A" UN196450 Fig. 4 12 Curve "A" UN197157 Fig. 3 12 Curve ''B" RECTIF"IER ( =~ 8 CELLS LEAD STORAGE BATTERY O.C. VOLTMETER 0-15 ANO 0-1~0 VOLTS 94 J "A' 90 I -;;:1a I' ~ ~74 I f J I er: w 70 J I I&. ' I er: I 62 ' I I 2 I j !>4 4 ' I 58 0-15 ANO 0-150 VOLTS ~ ,/ J G 66 w O.C'. VOLTMETER 1./ j _82 { D.C.MILL IAMME TE R ,_;-.........__..._...,0-1?> ANO 0-150 M.A. ~"":.A +._V _____~ , 6 8 10 12 MILL !AMPERES REVERSE Fig. 4 8 CELLS LEAD STORAGE BATTERY / ~P' I' 88 RECTIFIER "E! "/ / Fig. 3 . RESISTOR ABOUT 100-0HMS / '( Fig. 5 14 16 18 CURRENT - 6- 'U.S. & S. 2444-H FORWARD RESISTANCE TEST: Connect the rectifier into the circuit specified in Table II, first using the connections indicated by the solid lines. Adjust the resistor until the ammeter shows the current specified in Table II and read the voltmeter. Repeat the test with lead "X" connected to the other rectifier terminal as indicated by the broken line in the circuit diagram. The· voltmeter in either test should not read less than shown by Curve "A", nor more than shown by Curve "B" in the Figure specified in Table II for the 'temperature of the rectifier at the time the test is made. ' '' I.!'. U.S. & S. - 2444-H - 7 TABLE II Rectifier Pc. No. Test in Circuit of Amps. D.C. +\pply Curves of UN196315 Fig. 7 0.100 Fig. 9 UN196450 Fig. 7 0 •. 100 Fig. 8. UN197157 Fig. 6 0.150 Fig. 8 RECTIFIER ( 9$ 90 D.C.MILLIAMMETER 0-1!!»0 M.A. \ ~85 \ 0 ----1A ci:eo ~ ia.17$ ta: 70 la.I ~e~ -t;~o + ' l&I a:55 · D.C. VOLTMETER 0-3 VOLTS ' "A', 0.6 "I l , lll \. \ \ t. \ \ ' \ ~ \ o.e 0.7 0.9 1.0 FORWARD VOL TS 1.t I CELL LEAD STORAGE BATTERY Fig. 6 O.C.MILLIAMMETER 0-1!>0 M~A. /' Fig. 8 95 ' - \\ 90 .\'- 85 \ ''A" ·~ ~·· 2 +~-----~'I ~.:-- J '"--...._-+-_ _...., 1'\CELL D.C.VOLTMETER 0-3 VOLTS LEAD STORAGE BATTERY ~ 75 a: 70 u , t- l a: 55 \ ~ 65 u 60 w - l a : 80 \ \ ' 0.7 0.8 0.9 1.0 U ~ \ \ 12 1.3 1.4 1.!t 1.6 FORWARD VOLTS Fig. 7 Fig. 9 U.S. & S. - 8 - 2444-H 6. CALIBRATION OF RELAY IN COMBINATION WITH RECTIFIER Calibration should be made with the rectifier connected as shown in Fig. 2. Apply 60 cycles a-c. voltage to the coil terminal posts on the relay and charge at the normal voltage. Test that the release is not less than the value in Table Ill by reducing the voltage gradually until the armature starts to move. away from the stop-pin. At this energization the armature must continue its downward motion, opening all front contacts and closing the back contacts. After the release test, check that the pick-up is not more than the value in Table III by opening the circuit for one second, again applying the voltage and increasing gradually until the armature moves upward until the auxiliary back contact springs start to open away from the silver tips. At this energization the · armature must move to open the back contacts, picking up to the stop-pin posi tion to fully compress the front contacts. If full contact pressure is, not obtained at the pick-up energization, or if full release is not obtained when the armature starts to move away from the stop-pin, it will be necessary to change the contact adjustment and the holddown spring adjustment to give proper operation. The characteristics of the rectifiers used on these relays are such that they tend to compensate for the change in resistance of the coils with variations in temperature, thus maintaining the pick-up and release calibration substantially constant over the normal range of operating temperatures. At extremely high (150 deg. F.)·or extremely low (-30 deg. F.) temperatures, the values would tend to be slightly higher than at normal temperatures, particularly with rectifiers that have been in service for several years. In order to provide margins to insure that the relay will pick up at normal operating voltage under extreme temperature conditions,. it is recommended that the pick-up value at ordinary temperatures be kept below the maximum value as given in the table, which is 90% of the normal operating voltage. ·7. CONT ACT RESISTANCE Resistance of front contacts should be measured with the armature against the stop pin. The initial cleaned resistance of contacts should not exceed the values given in the following table: FRONT CONTACTS · Power Transfer Silver to silver-impregnated carbon Silver to silver 0.05 ohm 0.02 ohm Standard Low Voltage Silver to silver-impregnated carbon 0.09 ohm U.S. & S. - Rev. 7/83 2444-H - 9 - BACK CONTACTS Power Transfer Silver to silver-impregnated carbon Silver to silver 0.05 ohm 0.02 ohm Standard Low Volt_age Silver to silver 0.03 ohm TABLE III CALIBRATION VALUES FOR DN-1 lP 4 POINT POWER TRANSFER RELAY AIR GAP - 0. 035" PARALLEL Normal AC Volts -, Res. of Coils-Ohms Rectifier Pc. No. Min. Drop-Away With Cont. Press. Volts (AC) Max. P. U. and Full Stroke Volts (AC) 8 45 - 45 UN197157 5.6 7.2 10 75 - 75 UN196450 7.0 9.0 12 125 -125 UN196315 8.4 10.8 TABLE IV. CALIBRATION VALUES FOR DN-llP 6 POINT POWER TRANSFER RELAY WITH 4F-4B POWER TRANSFER CONTACTS AND 2F-2B STANDARD L. V. CONTACTS. AIR GAP - 0.025" PARALLEL. Res. of Coils-Ohms Rectifier Pc. No. Min. Drop-Away With Cont. Press. Volts (AC) 8 45 - 45 UN197157 5.6 7.2 10 75 - 75 UN196450 7.0 9.0 12 125 -125 UN196315 8.4 10. 8 Normal AC Volts Max. P. U. and Full Stroke Volts (AC) CAUTION The "S" contact of this relay is designed to open slightly in advance of the other contacts. The purpose of this advance opening is to eliminate intermittent opening and closing of the power contacts due to high resistance or poor power supply regulation. Eguipment damage may result if the "S" contact is employed for any purpose other tha~ its intended use.